Method of making fireproof and esthetic acoustic btjildina material



Dec. 28 1926. 1,612,212

F. PEANO METHOD OF MAKING FIREPROOF AND AESTHETIC ACOUSTIC BUILDING MATERIAL AND ARTICLE MADE THEREBY Filed March 2, 1925 j/WENTUR FELIX PEA/V0 w efiiiw W 71? 1 W Patented Dec. 28, 1926.

. TA-TES FELIX PEANO, 0F HAWTHORNE, CALIFORNIA.

METHOD OF MAKING FIREPROOF AND ESTHETIC ACOUSTIC BUILDING MATERIAL AND ARTICLE MADE THEREBY.

Application filedllttarch 2, 1925. Serial. No. 12,593.

A porous volcanic rockknown as scoria or volcanic glass is found in nature, but many times it is not found in the proper shape or size, nor is it sufiiciently accessible to be commercially valuable and furthermore the supply is limited.

An object of this invention is to artifically produce a porous rock known as scoria.

Another object is to provide means to form the scoria into large slabs or panels.

A still further object is to provide means to decoratively improve the scoria.

A feature of the invention is to provide large sheets or panels of scoria for use as acoustic or heat screens.

Other features are cheapness, ease and simplicity in manufacture.

An object is to make sculptured embellishments used for interiors of an acoustic nature.

Other objects, advantages and features of invention may appear from the accompanying drawing, the subjoined detailed description and the appended claims.

In the accompanying drawing I have illustrated several adaptations of my method of making novel acoustic and aesthetic screens.

Figure 1 is a perspective view of a table used for making a thin fireproof and acoustic screen. A portion of the ingredients used for making the screen are on the table and a fragment of the screen is broken away to expose the ingredients underneath.

Fig. 2 is a section on line M, Fig. 1', showing the ingredients on both sides of th screen.

Fig. 3 is a perspective view of a fireproof screen having a. sculptured surface.

Fig. 4 is a section on line :0", Fig. 3.

Fig. 5 is a plan View of a scoria slab or screen decorated by application of colors.

Fig. 6 is a section on line :12, Fig. 5.

Fig. 7 is a sectional view analogous to Fig. 6, showing a-section through a reinforced screen.

The table 1 is formed of a heat resisting material such as metal, fire brick, etc., and is of sufiicient size to form a panel of scoria of a practical size. The table 1 has side walls 1' and preferably fire bricks a are supported on the table surface. The side walls retain the layer of scoria fragments 2 that are spread over the table to a suitable depth, and the screen 3 is then spread over this layer and secured tliereto either by a suit able cement or glue, without the addition of heat, or by heating with. the addition of a flux, such as borax, sub-nitrate of bismuth, or any other of the ingredients in the manufacture of lass.

When the screen is secured by a cement or glue the screen is preferably immersed y in a bath of the desired cement and then such screen is laid upon the scoria on the table or the scoria is placed upon the screen so that the adhesive cement will secure the contacting particles of scoria to the screen.

When the screen is secured to the scoria by heat and fluxes I use a scoria that has first been screened to a mesh approximately 10% smaller than the mesh of the screen to be used as a reinforcement. I then push or work the screen into such layer of scoria particles 2 so that a particle of scoria protrudes through each mesh of the wire screen 3. I then mix pulverized scoria and a suitable flux together and sift the same evenly over the whole surface. I then 'vitrify the scoria. particles to the screen, giving me a product similar to that shown in cross section in Fig. 7

A decorative sculpture 4 as shown in Figs. 3 and 4, may be obtained by first providing a perforated metallic plate or screen 5 that has been stamped or formed from a thin sheet or screen into the desired image and then filling the back or concave part 6 with crushed scoria of a lar 'er mesh than the perforations in the metal ic image.

I then place a fireproof sheet over the filled-up aperture and invert the image, sheet and scoria therein, supporting such sheet upon asurface.

The scoria interposed between such sheet and image is made to settle so as to leave room for the introduction through the perforations or mesh of the screen 50f scoria particles 2 having a mesh a trifle smaller than the mesh of the plate or screen 5.

Such particles are secured to the screen 5 by either cement or a suitable flux and vitrification, and the crushed scoria of lar er mesh than the perforations serves as a fi er and does not appreciably adhere'to the metallic plate 5.

I have discovered that the scoria may be artificially prepared, and in my method of making artificial scoria I prefer to use obsidian, but any rock containing a volatile substance therein may be used.

The obsidian or other suitable rock is subjected to a heat of about 3500 F. more or less, which expels the sulphur, carbon, or other undesired volatile materials, leaving a light porous silicious substance commonly known as scoria. Any rock requiring a much greater heat than 8500 F. to volatilize the undesired portions therein would not be de sirable due to the increased cost of treatment.

However, it may be that the required temperature will vary and in some instances be lower or higher than 3500 F. In treating the rock, I use a kiln fed by the cheapest combustible obtainable, which will give the desired heat of approximately 3500 F and I then place the rock in such kiln and bring the temperature thereof to the desired point, and thereby volatilize the undesired portions and obtain the desired sponge like silicious structure of the rock freed of'the undesired parts.

The required spongy substance or scoriamay be readily cut into any desired shape by a suitable metallic instrument, such as a saw.

For use as a screen thin slabs or panels 7 may be cut from the large mass of scoria obtained from the kiln.

The natural or artificial scoria contains about 90% of silica; aluminum, lime, sulphate, and other substances about 10%. It will Withstand a compression pressure of about 200 pounds per square inch.

As both the natural and artificial scoria is grey in color, which possibly would not blend well with a color scheme in exposed places such as walls, screens, etc., I have discovered a novel method of decorating and embellishing such scoria. For this purpose, after the panels are cut, I color the exposed surface thereof with any desired color, as follows: a metal or a metallic salt is spread over the surface of the panel and by appl ing a flame the vapors of ,the salt or t e metal are fused into the softened scoria, thus obtaining a colored effect. For example, a zinc salt will give a white color; silver chloride a greenish white; gold chloride either purple or gold.

For further decorative effects crushed carborundum or nuggets of other suitable material, such as copper, may be fused to the panel.

The various small fragments of artificial scoria may also be utilized and formed into panels as hereinbefore set forth.

The scoria particles may or ma not be stained prior to application to reinforcing screen or to the sculptured surface.

From the foregoing it will be apparent that I have produced a panel that has an acoustically porous body.

As a further artistic composition of matter I mold of reinforced plaster of Paris,

Portland cement, or magnesite, a sculpture having the desired outline and while the plaster is still plastic I press into the exposed surface particles of scoria, which are secured thereto when the plaster sets. This scoria may then be Vitrified or otherwise decorated as above setforth without damage to the plaster.

The sculpture may also be made solely of plaster of Paris and provided with a scratched surface and after the same has set, I may decorate the surface thereof by. fastening scoria to such surface with the aid of any suitable binder and I then vitrify or otherwise decorate such scoria.

I claim:

1. The method of forming a panel of building material comprising placing a metal screen on a layer of scoria fragments, and then securing such fragments to said screen by vitrification.

2. The method of forming a panel of building material comprising first placing a metal screen upon scoria fragments, of a mesh smaller than the mesh of said screen, and then applyin heat of a temperature lower than the me ting point of said screen to bond the scoria to the screen.

3. The process of forming a panel of buildingmaterial comprising placing a uniform layer of scoria fragments upon a fireproof table, then placing a perforated screen on said scoria, then working said screen intosaid scoria sov that particles of said scoria protrude through the perforations of said screen, then sifting scoria particles and a flux over said screen, and then securing said scoria to said screen by vitrification.

4. The process of forming a panel of building material comprising supporting a layer of scoria fragments on a surface; then placing a perforated screen on said fragments. then covering said screen with flux treated scoria, then heating the scoria to bond said scoria to said screen by vitrification; and then vitrifying to the surface of the resulting panel an iridescent color.

5. A panel consisting of a layer of scoria fragments, a binder, and a metal screen to which said scoria is secured.

6. The process of forming a panel, which consists in placing a layer of uniform sized scoria fragments on a fireproof table, said fragments being smaller than the mesh of a screen placed thereupon, placing a layer of powdered scoria and binder over said screen and scoria layer, and heating the whole to bind the scoria to the screen by vitrification.

7. A decorative scoria panel comprising a perforated metallic plate formed with a sculpturally decorative surface, said panel being covered with scoria, and means to secure said scoria to said plate.

8. The method of forming a decorative ,scoria fragments to the front surfaceof said plate.

9. The method of forming a decorative 1 of a perforated metallic.

panel consistin plate-formed wlth a sculpturally decorated surface, placing scoria fragments over the back surface of said late, and securing scoria fragments to the ront surface of said plate, and entirely covering said front surface, the scoria fragments being of smaller mesh than the perforations in the plate.

10. An article ofmanufacture, comprising relatively thin anels of 'scoria, the surface thereof being ecorated by metallic particles'secured thereto.

11. The method ofmaking a building material panel comprising securing to a perforated metal screen, fragments of scoria.

In testimony whereof, I have hereunto set my hand at Los Angeles, California, this 18th day of February, 1925.

FELIX PEANO. 

